Pipeline insertion system

ABSTRACT

A pipeline insertion system may include an insertion device outside a tunnel that includes an insertion device frame and a movable clamp device in slidable engagement with the insertion device frame. A drive may cause the movable clamp device engaged with a pipeline to move between a first position and a second position along the frame. Inside the tunnel, the system may also include a plurality of support frames remote from the insertion device and remote from each other which support the pipeline on bearings as the pipeline is pushed (or pulled) by the insertion device through the bores of a plurality of housing segments mounted in the tunnel. A controller is operative to control the drive and the movable clamp device responsive to transducers which measure pipeline slippage, thrust force, and clamping pressure.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/508,613 filed May 8, 2012, which is a U.S. National Stage ofInternational PCT Application No. PCT/US2011/038356 filed May 27, 2011,which claims benefit of U.S. Provisional Application No. 61/349,759filed May 28, 2010, which applications are hereby incorporated herein byreference in their entirety.

BACKGROUND

Pipelines for moving natural gas, oil, and other gases and fluids may bemounted inside tunnels, through wetlands, across shorelines, and otherenvironments with limited accessibility to construct the pipeline.Depending on the location, such pipelines may need to extend for manykilometers through such environments. For instance, pipelines in atunnel beneath a large city may have lengths of eight or morekilometers.

To construct such a pipeline within a tunnel, the tunnel may be boredwith a tunnel boring machine (TBM). Once the tunnel is bored (or as thetunnel is being bored) one or more pipelines may be installed in thetunnel. Pipelines installed in such tunnels are typically constructedout of many pipeline segments that are welded together to form agenerally straight run of the pipeline.

Unfortunately, the environmental conditions within the tunnel oftenimpede the productivity of welders and other construction crewsinstalling the pipeline. Environmental conditions associated withwetlands and shoreline approaches also impede the productivityassociated with the installation of a pipeline. Thus there is a need forimprovement to existing systems for installing pipelines.

SUMMARY

The following is a brief summary of subject matter that is described ingreater detail herein. This summary is not intended to be limiting as tothe scope of the claims.

Described herein are various technologies relating to installingpipelines. An example system may correspond to a pipeline insertionsystem. Such a system may include an insertion device that includes aframe, a movable clamp device in slidable engagement with the frame, andat least one drive. The system may also include at least one controllercomprising one or more computers, processors, and/or other electricalcomponents that are operatively configured to operate the insertiondevice to move a pipeline and to monitor the operation of the system.

The at least one controller is operatively configured to cause the atleast one drive to move the movable clamp device between a firstposition and a second position along the frame. Also, the at least onecontroller is operatively configured to cause the movable clamp deviceto change between a first state and a second state. In the first state,the movable clamp device is operative to clamp (i.e., rigidly engage andgrip) at least one portion of a pipeline received by the pipe insertiondevice and prevent relative movement between the movable clamp deviceand the pipeline. In the second state, the movable clamp device isoperative to release the at least one portion of the pipeline and permitrelative movement between the movable clamp device and the pipeline.

This described system may also include a plurality of housing segments.Each housing segment may be comprised of concrete or other material andmay include at least one bore therethrough for receiving portions of thepipeline. Also the system may include a plurality of support frames.Each support frame includes a channel therethrough with at least onebearing mounted therein for receiving portions of the pipeline inoperatively sliding connection with the at least one bearing.

In this described embodiment, the support frames are respectivelypositioned between the ends of the bores of adjacent housing segments,such that the bores of the housing segments and the channels of thesupport frames are aligned to receive the pipeline extending in asubstantially straight line through a sequence of many pairs of adjacenthousing segments and support frames.

During operation of the system, the at least one controller isoperatively configured to cause the movable clamp device to change tothe first state to clamp at least one portion of the pipeline and tocause the at least one drive to move the movable clamp device from thefirst position to the second position in order to move portions of thepipeline within at least one bore of at least one of the housingsegments and at least one channel of at least one of the support frames.Also, the at least one controller is operatively configured to cause themovable clamp device to change to the second state and to cause the atleast one drive to move the movable clamp device in a reverse directionfrom the second position to the first position without moving thepipeline relative to the housing segments and support frames.

In this described embodiment, the at least one controller is operativelyconfigured to operate the insertion device for many insertion cycles toincrementally push the pipeline through the bores of many housingsegments. Such housing segments may have lengths to accommodate theplacement of a sufficient number of support frames between ends ofadjacent housing segments in order to support moving a pipeline for adistance of several kilometers through the bores of the housing segmentswithout the pipeline buckling and with no (or at least minimal) contactbetween the outer surfaces of the pipeline and the inner surfaces of thebores of the housing segments.

When installing a new pipeline, after one or more insertions of portionsof the pipeline (via the movable clamp device moving one or more timesfrom the first position to the second position), one or more additionalpipeline segments may be welded to the portion (i.e., outer end) of thepipeline that extends outside the housing segments. Once the pipelinehas been lengthened in this manner, the insertion device may be operatedagain to move the movable clamp device one or more times in order toinsert more of the pipeline into the bores of the housing segments. Thisprocess may be repeated for as many insertion cycles as needed to insertthe required length of pipeline in the tunnel.

Also, it should be appreciated that in the described embodiment, the atleast one controller may be operatively configured to operate theinsertion device to remove a pipeline out of the housing segments. Thismay be carried out via the movable clamp device moving one or more timesfrom the second position to the first position to pull the pipelineoutwardly from the bores of the housing segments. One or more segmentsof the removed pipeline may be cut off of the pipeline. Once thepipeline has been shortened in this manner, the insertion device may beoperated again to move the movable clamp device one or more times inorder to pull additional portions of the pipeline out of the bores ofthe housing segments. This process may be repeated for as manyextraction cycles as needed to remove and disassemble the pipeline.

Other aspects will be appreciated upon reading and understanding theattached figures and description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an example pipeline insertion system.

FIG. 2 is a perspective view of an example embodiment of an insertiondevice.

FIG. 3 is a perspective view of an example movable clamp device of theinsertion device.

FIG. 4 is a front plan view of an example movable clamp device.

FIG. 5 is a perspective view of an example arrangement of housingsegments and support frames.

FIG. 6 is a perspective view of an example support frame mounted betweenends of adjacent housing segments.

FIG. 7 is a perspective view of an example support frame withoutpipelines and housing segments.

FIG. 8 is a front plan view of an example support frame mounted in atunnel.

FIG. 9 is a flow diagram that illustrates an example methodology foroperating a pipeline insertion device to insert a pipeline.

FIG. 10 is a flow diagram that illustrates an example methodology foroperating a pipeline insertion device to extract a pipeline.

DETAILED DESCRIPTION

Various technologies pertaining to pipeline installations will now bedescribed with reference to the drawings, where like reference numeralsrepresent like elements throughout. In addition, several functionalblock diagrams of example systems are illustrated and described hereinfor purposes of explanation; however, it is to be understood thatfunctionality that is described as being carried out by certain systemcomponents and devices may be performed by multiple components anddevices. Similarly, for instance, a component/device may be configuredto perform functionality that is described as being carried out bymultiple components/devices.

With reference to FIG. 1, an example pipeline insertion system 100 thatfacilitates moving a pipeline over several kilometers is illustrated. Inan example embodiment, the system 100 includes an insertion device 102.As explained in more detail below, this described insertion device isoperative to move a pipeline in a generally straight line into and outof a tunnel or other location (e.g., wetlands, shoreline). Such apipeline may correspond for example to pipeline with a 30 inch outerdiameter, 0.500 inch wall thickness API-5L-X70 steel pipe. However, itis to be understood that in alternative embodiments, other sizes ofpipelines may be used.

The example system may include at least one controller 126 that isoperative to control one or more features of the insertion device. Sucha controller may correspond to one or more processors and associatedelectrical components that are operatively configured to cause featuresof the insertion device to operate. For example, the system may includea controller in the form of a computer with at least one processor 160therein. The computer may include software 166 which is operativelyconfigured to control hardware in the insertion device (e.g., motors,pumps, valves, etc.). In another example, the controller may include aprocessor such as a programmable logic controller with firmwareconfigured to operate the hardware in the insertion device.

In example embodiments, the controller may also be operative to receivesignals from sensors 128 (e.g., transducers) mounted to the hardwarecomponents of the insertion device. As explained in more detail below,the controller may be responsive to such sensor signals to control howthe hardware in the insertion device operates. The controller may alsobe operative to communicate information regarding the operation of thehardware and the signals from the sensors to one or more local and/orremote output devices 162 (e.g., display screen, visible/audiblealarms), to enable users to monitor the insertion device. Furthermore,the controller may be in operative connection with one or more inputdevices 164 (e.g., touch screen, keyboard, mouse) through which a usermay provide inputs that control how the controller operates theinsertion device.

In an example embodiment, the insertion device 102 includes a frame 104.Mounted in slidable engagement with the frame is a movable clamp device106. The at least one controller is operatively configured (e.g.,programmed) to cause the movable clamp device to change between a firststate in which the movable clamp device clamps a portion of the pipelinein rigid engagement therewith, and a second state in which the movableclamp devices releases the portion of the pipeline from rigid engagementwith the movable clamp device.

When the movable clamp device is in the first state, the appliedclamping forces are operative to prevent movement of the pipelinerelative to the movable clamp device. Also, it should be understood thatthe controller may be operative to vary the amount of clamping forcesapplied by the clamp device depending on the diameter, weight, andcurrent length of the pipeline, and the amount of force needed to movethe pipeline. Thus as used herein, the first state corresponds to whenthe movable clamp device is operatively providing sufficient clampingforces to enable the pipeline to be moved without the pipeline slippingrelative to the clamp device.

In example embodiments, the movable clamp device may include a pluralityof hydraulic cylinders which are operative to cause movable portions 190(e.g., pads) of the movable clamp device to move to rigidly clamp thepipeline. Hydraulic pumps and valves used to operate the hydrauliccylinder may be controlled by the described controller.

In addition, the described insertion device may include one or moredrives 114 such as hydraulic motors. The controller may be operativelyconfigured to cause the drives to move the movable clamp device betweena first position 108 and a second position 110 on the frame. Asexplained in more detail below, in example embodiments the insertiondevice may include rack and pinion gear assemblies which enable thedrive to move the movable clamp device along the frame. However, it isto be understood that alternative embodiments may employ other types ofgears or other mechanical assemblies that are capable of moving themovable clamp device (and a pipeline clamped therein) with respect tothe frame.

As illustrated in FIG. 1, the described system may be used to insert apipeline in a bored out underground tunnel 130 or other pipelineapplication. Such a tunnel may be produced by a tunnel boring machine.As the tunnel is being produced or after the tunnel is produced, aplurality of pipeline housing segments 122 may be mounted inside thetunnel. Such housing segments may each include at least one bore 124(i.e., a hollow passageway) therethrough. However, in a typical example,the segments may include three or more bores therethrough. Also, itshould be understood that the term “bore” as used herein with respect tohousing segments does not require that this bore be formed through adrilling process. Rather a bore is defined herein as a hollowpassageway, which may be generated using any applicable process,including drilling and/or via forms, molds or other casting techniquesas the housing segments are produced.

In example embodiments, the housing segments may correspond topre-casted concrete segments that are transported into the tunnel andmay be mounted serially in a manner such that the respective bores ineach housing segment are axially aligned with the respective bores ineach adjacent housing segment. In alternative embodiments the housingsegments may be formed inside the tunnel by providing concrete intoappropriate forms.

In addition, it should be appreciated that in some embodiments, thebores may include inner walls comprised of the concrete of which thehousing segment is constructed. However, in alternative embodiments thewalls of the bores of the housing segments may correspond to pipes madeout of other materials (such as steel pipes) which are embedded in theconcrete body of the housing segment.

Once the housing segments are mounted in the tunnel, the bores of thehousing segments provide a straight passageway through which a straightrun of pipeline may be inserted. Also, in an environment such as atunnel, the described housing segments may correspond to floor segments.For example, the upper surfaces of the housing segments may be generallyflat, and thus may correspond to a portion of roadway that is capable ofaccommodate movement of people and/or vehicles through the tunnel overthe floor segments and pipelines contained therein. However, it is to beunderstood that in alternative embodiments the pipeline housing segmentsmay not include an upper surface that can serve as a roadway for avehicle.

As illustrated in FIG. 1, the described system may further include aplurality of support frames 116. Each support frame may include achannel 118 therethrough with at least one bearing 120 mounted thereinfor receiving portions of the pipeline in operatively sliding connectionwith the at least one bearing 120. The support frames may berespectively positioned in the tunnel between the bores of adjacenthousing segments, such that the bores of the housing segments and thechannels of the support frames are aligned to receive the pipelineextending in a substantially straight line therethrough. In thisdescribed embodiment, the bearings 120 of the support frames arepositioned in a manner to fully or at least substantially support therun of the pipeline so as to prevent (or at least minimize) portions ofthe pipeline sliding against the inner surface of the bores of thehousing segments.

As shown in FIG. 1, the housing segments may be produced (e.g., casted)to include a base 170 upon which the support frames may be mounted. Suchbases 170 may be provided with a sufficient height relative to the bores124 and such support frames may be constructed with appropriatedimensions, such that placement of the support frames on the bases mayresult in the channels 118 of the support frames being substantiallyaligned with the bores 124 of the segments (with minor positionaladjustments).

In this regard, it should be understood that appropriate surveyingequipment (e.g., lasers), shims, and other alignment tools and devicesmay be used to accurately place the channels of the support frames inthe required amount of alignment with the bores of the housing segmentsto be within the tolerances needed for the particular pipelineapplication. Also, it should be appreciated that the housing segmentsmay be appropriately surveyed and aligned to place their respectivebores in axial alignment within the tunnel.

Also, it should be appreciated that the shapes of the bores and channelsdescribed herein may not be cylindrical. Thus as used herein,substantial alignment of the bores and channels corresponds to analignment that is sufficient to provide at least one passageway throughthe described bores and channels, which passageway is capable ofreceiving a substantially straight cylindrical pipeline therethrough.

In example embodiments of the described system, the insertion device 102is also positioned and aligned to properly direct portions of thepipeline into (and/or out of) the bores and channels of the housingsegments and support frames. In an example embodiment, the insertiondevice may include alignment devices 172 that are operative toselectively horizontally and vertically raise/lower portions of thedescribed frame to axially position and align openings through themovable clamp device 106 with the bores 124 of the housing segments 122mounted in the tunnel 130.

Once the insertion device is properly positioned, pipeline segments maybe mounted in the movable clamp device. The controller 126 may then beoperated to cause the movable clamp device to change to the first state(which clamps the pipeline) and to cause the at least one drive to movethe movable clamp device from the first position 108 to the secondposition 110 in order to begin the process of moving portions of thepipeline within the bores of housing segments and the channels of thesupport frames.

After the movable clamp device has moved to the second position, thecontroller is operative to cause the movable clamp device to change tothe second state (which releases the pipeline) and to cause the at leastone drive to move the movable clamp device from the second position backto the first position without moving (or at least without substantiallymoving) the pipeline relative to the housing segments and supportframes.

As used herein, the process of pushing the pipeline forward via themovable clamp device moving from the first position to the secondposition (in a first direction), followed by moving the movable clampdevice (but not the pipeline) back to the first position (in a seconddirection opposite the first direction), is referred to herein as aninsertion cycle. After one or more insertion cycles, one or moreadditional pipeline segments 180 may be welded on to the end of thepipeline 112 and then the insertion devices may be operated again (forone or more insertion cycles) to move the lengthened pipeline furtherinto the housing segments. The periodic operation of the insertiondevice and the welding on of additional pipeline segments may continueuntil the desired run of pipeline has been moved through the desirednumber of housing segments and support frames.

As can be appreciated, this described process may be carried out in thereverse direction to extract the pipeline from the housing segments. Asused herein the process of pulling the pipeline outwardly via themovable clamp device moving (in first clamped state in the seconddirection) from the second position to the first position, followed bymoving (in the first direction) the movable clamp device (but not thepipeline) in the (second released state) back to the second position, isreferred to herein as an extraction cycle. After one or more extractioncycles, one or more pipeline segments 180 may be cut off the end of thepipeline 112 and then the insertion devices may be operated again (forone or more extraction cycles) to move the shortened pipeline furtherout of the housing segments. The periodic operation of the insertiondevice and the cutting off of pipeline segments may continue until thedesired run of pipeline has been removed from the housing segments andsupport frames.

In an example embodiment, in order to prevent the pipeline from moving(when the movable clamp device is in the second released state and movesbetween the first and second positions) the insertion device may includea further stationary clamp device 150 to hold the pipeline in placewhile the movable clamp device returns to another position. Thecontroller 126 may be operative to cause the stationary clamp device 150to change to the first state (i.e., the clamped state) to rigidly holdthe pipeline in place on the frame while the movable clamp device 106 isreturned to its applicable starting position for another insertion (orextraction) cycle. Also, prior to the movable clamp device 106 movingthe pipeline (either as an insertion or extraction cycle) the controller126 is operative to cause the stationary clamp device 150 to change tothe second state (i.e., the released state) to permit the pipeline tomove relative to the stationary clamp device 150 as it is pushed (orpulled) by the movable clamp device.

Referring now to FIG. 2, there is illustrated a perspective view of anexample embodiment of an insertion device 200. FIG. 2 illustratesexamples of the previously described hardware components that may beincluded in an insertion device. Such hardware may include a movableclamp device 202 which is mounted in slidable connection with aninsertion device frame 204. Here the movable clamp device may include acarriage 206 that is in slidable engagement (e.g., via a plurality ofrollers and/or bearings 232) with rails 208, 210 integrated into theframe 204 of the insertion device.

In order to move the movable clamp device 202 relative to the frame, thecarriage 206 may include drives in the form of several motors 212 suchas hydraulic motors. The hydraulic motors may be orientated to rotaterespective pinion gears (312 shown in FIG. 3) adjacent a gear rack 214mounted between the rails 208, 210. The previously described controllermay be operative to control hydraulic pressure from a hydraulic pump toselectively cause the hydraulic motors to move the carriage 206 alongthe frame 204.

FIG. 2 also illustrates an example of a stationary clamp device 230which is mounted in rigid engagement with the frame 204. In additionFIG. 2 illustrates examples of alignment devices that are usable toselectively position and align the inserter device. Here the alignmentdevices may include hydraulic dollies 216 and 218 to selectively movethe insertion device laterally. Also, the alignment devices may includehydraulic jacks 220, 222 comprising vertically orientated hydrauliccylinders 224 to selectively move the insertion device vertically.

When initially positioning the insertion device 200 on a concrete pad orother foundation, the at least one controller may be operated to causethe dollies 216, 218 to move the insertion device laterally in order tohorizontally align the openings of the movable clamp device and thebores of the housing segments. Subsequently, the at least one controllermay be operated to selectively and individually cause the hydrauliccylinders 224 to raise or lower each side of each hydraulic jack 220,222 of the insertion device to vertically align and orientate theopenings in the movable clamp device 202 with the bores of the housingsegments.

Referring now to FIG. 3, there is illustrated a perspective view 300 ofthe previously described movable clamp device 202. FIG. 3 shows thehydraulic motors 212 which are operative to rotate respective piniongears 312 (along the gear rack 214 shown in FIG. 2).

Also, as shown in this example, the movable clamp device 202 may includea plurality of movable portions 302 that are positioned around at leasta portion of the opening 304 in the movable clamp device that receivesthe pipeline. Such movable portions 302 may correspond to replaceablebonded friction shoes (also referred to herein as pads).

Also as illustrated in FIG. 3, the described movable portions 302 maygenerally be mounted to move inwardly to contact the top half (i.e., top180 degrees) of the cylindrical surface of the pipeline. The bottom halfof the pipeline (i.e., the bottom 180 degrees) may be supported bystationary portions 308 of the movable clamp device. Such stationaryportions may also include replaceable bonded friction shoes/pads aswell.

In this described embodiment, the movable portions 302 may be moved byrespective hydraulic cylinders 306. Such hydraulic cylinders 306 may beselectively operated by the controller to control the amount of clampingforces applied to the pipeline by the movable portions 302. Thehydraulic cylinders 306 may be operative to move each respective movableportion 302 radially inwardly towards a respective stationary portion308 (on the opposite side of the pipeline) to clamp the pipeline in thepreviously described first state of the movable clamp device. Themovable portions 302 may also be moved radially outwardly to thepreviously described second state of the movable clamp device to releasethe clamping forces acting on the pipeline. In addition, it should beappreciated that the movable clamp device may include multiple sets ofrespective movable/stationary portions, which sets are positioned toclamp different portions of the pipeline in a longitudinal direction.

Referring now to FIG. 4, there is illustrated a front plan view 400 ofthe previously described movable clamp device 202 with a portion of thepipeline 402 clamped therein between the movable 302 and stationary 308portions (e.g., shoes, pads). FIG. 4 also shows an example of the mannerin which the carriage 206 of the movable clamp device may be mounted inslidable engagement with the frame 204 of the insertion device.

As discussed previously, the described pipeline insertion system mayinclude a plurality of housing segments that are mounted end to end in atunnel. FIG. 5 illustrates an example arrangement 500 of housingsegments 502, 504, 506 with three pipelines 510 inserted therethrough.FIG. 5 also shows examples of support frames 522, 524 mounted betweenends of the housing segments. As shown in this view, the support framesmay be located in gaps 530, 532 between the openings to the bores inadjacent housing segments. In order to enable the upper surface of thehousing segments to serve as a roadway, steel plates or other planarelements 540 may be placed across these gaps to cover the supportframes.

FIG. 6 shows a larger perspective view 600 of the support frame 522 thatis positioned between opposite facing ends 604, 606 of adjacent housingsegments 504, 502. As discussed previously, the housing segments mayinclude a base 522 that is operative to serve as a foundation for thesupport frame 602. FIG. 6 also illustrates that a support frame may beconstructed to support a plurality of pipelines (such as three or othernumber of pipelines) in side by side relation.

In example embodiments, the housing segments may correspond toseparately poured units that are mounted in the tunnel in end to endrelation. However, it is also to be understood that one or more housingsegments may be formed integrally with each other as part of a commonand continuous unit, rather than as separate components. In such cases,the term housing segment refers to each respective portion of theintegral unit that includes one or more bores therethrough withrespective bore ends that are exposed for mounting a support frameadjacent thereto. Also in this described embodiment, the bases 612 thatserve as a foundation for the support frames may correspond to a portionof the continuous unit that integrally includes adjacent pairs ofhousing segments.

Referring now to FIG. 7, there is illustrated a perspective view 700 ofthe support frame 522 without the pipeline and housing segments. Herethe support frame is shown including three channels 702, 704, 706through which pipelines may be inserted. In this example, each channelincludes eight bearings, four bearings 720 of which are positioned tosupport the lower portion of the pipeline, and four bearings 722 ofwhich are positioned to guide an upper portion of the pipeline.

In this described embodiment, the bearings 720, 722 mounted in eachchannel correspond to ball transfer type rollers. Such bearings mayinclude a load-bearing spherical ball mounted inside a housing, whichball is supported by smaller ball bearings. However, it is to beunderstood that in alternative embodiments, other types and/or numbersof bearings may be used (e.g., contoured roller bearings) that areoperative to support and/or guide the pipeline through the channel inthe support frame.

FIG. 8 illustrates a cross-sectional view of a tunnel 800 showing themanner in which the support frame 522 may be mounted on a housingsegment base 522 adjacent an end 606 of the housing segment 504 throughwhich three pipelines 810, 812, 814 extend therethrough and throughrespective bores of the support frame. As shown in FIG. 8, the bearings830 in each channel may be mounted such that directions 832 normal tothe most inwardly extending surfaces of their respective rollingelements (i.e., the top of the spherical ball) are orientatedsubstantially radially with respect to the adjacent outer surfaces(and/or central longitudinal axis) of a pipeline 810, 812, 814 that isintended for use with the support frame. However, it should beappreciated that alternative embodiments with the same or differenttypes of bearings may mount the bearings in different positionsand/orientations.

In general, the frame supports are constructed to prevent the pipelinesfrom contacting the inner surfaces of the bores of the housing segments.However, gravity and errors in aligning new pipeline segments mayproduce a pipeline which sags or bows upwardly a small amount to scrapeportions of the inner walls of the bores of the housing segments. Inexample embodiments, the lower most portions 840 and the upper 842 mostportions of the surfaces of the pipeline may experience the most wear inthis regard, which results in non-smooth surfaces in these areas. Tominimize the wear such non-smooth surfaces of the pipeline may impact onthe bearings, the bearings may be mounted in locations of the supportframe that are axially offset from these expected wear zones.

Thus as shown in FIG. 8, in an example embodiment, the lower bearings720 in each channel may be mounted beneath portions of the lower half ofthe pipeline (to supportingly receive the pipeline) in locations thatare offset from the lower most portion 840 of the outer surface of thepipeline. Similarly the upper bearings 722 in each channel may bemounted above portions of the upper half of the pipeline in locationsthat are offset from the upper most portion 842 of the outer surface ofthe pipeline. However, it is to be understood that in alternativeembodiments, the bearings may be arranged in other locations around theinterior of the channels based on the load support characteristics ofthe particular application of the pipeline insertion that is involved.

In addition, the lower bearings 720 and upper bearings 722 in eachchannel may be mounted at positions such that not all of the bearings ina channel are capable of contacting the surfaces of the pipeline at onetime. Thus when the pipeline 812 is in contact with the lower bearings720, a gap will be present between the upper bearings 722 and thesurfaces of the pipeline. Similarly, if the pipeline includes a portionthat bows upwardly in the channel of the support frame to contact theupper bearings 722, there will be a gap between the lower bearings andthe surfaces of the pipeline.

In example systems, the amount of force required by the insertion deviceto push a pipeline through the bores of the housing segments willincrease as the pipeline is lengthened. To minimize the rate of increaseof the amount of force that is needed to push the pipeline, the lengthsof the housing segments and thus the distances between support framesmay become shorter in locations farther into the tunnel compared tolocations closer to the insertion device. For example, the lengths ofthe housing segments near the entrance to the tunnel adjacent theinsertion device may be on the order of ten meters, whereas the lengthsof the housing segments four kilometers into the tunnel may be on theorder of eight meters, and whereas the lengths of the housing segmentseight kilometers into the tunnel may be on the order of six meters. Thusin this described arrangement, the farther the pipeline is pushed intothe tunnel, there will be an increase in the number of bearings used tosupport a given length of the pipeline at the leading end of thepipeline (compared to the trailing end). Alternatively in anotherembodiment there may be an increase in the number bearings used tosupport a given length of pipeline at the trailing end of the pipelinecompared to the leading end. Also in example embodiments the lengths ofthe housing segments may be substantially uniform for portions and/orall of the length of the desired pipeline. In addition, to minimize theprobability of the leading edge of the pipeline from becoming lodgedagainst a support frame or housing segment due to sagging of the frontof the pipeline, the leading end of the pipeline may include a roundedor tapered cap. Such a cap may assist in guiding the leading edge of thepipeline into the channel of a support frame or opening into a bore of ahousing segment.

As discussed previously, the described example pipeline insertion systemmay include a plurality of different sensors on the insertion device.Sensors may also be mounted adjacent one or more of the support frames.The described controller may be operatively configured to use theinformation acquired by such sensors to adjust how the controlleroperates the insertion device and to provide an operator (or otherparty) with information on the operation of the system.

For example, each set of movable portions (e.g., shoes/pads) of themovable clamp device may be associated with a respective pressure sensorthat is operative to measure the amount of pressure being placed on theadjacent surfaces of the pipeline by the respective movable portion.Such pressure sensors may correspond to transducers that arerespectively mounted in the respective hydraulic circuits for eachrespective hydraulic cylinder that is used to move the shoes/padsadjacent the surface of the pipeline.

Also, the insertion device may include a movement sensor that isoperative to detect relative movement (i.e., slippage) between themovable clamp device and the pipeline. In addition, the insertion devicemay include a thrust sensor that is operative to measure the amount ofresistance force that is being experienced by the drives (e.g.,hydraulic motors) when moving the pipeline with the movable clampdevice. Such a thrust sensor may correspond to a transducer that ismounted in the hydraulic circuits for one or more of the describedhydraulic motors that move the movable clamp device. In addition, it isto be understood that alternative embodiments may include other types ofsensors (e.g., mechanical, optical, electronic) which carry outcorresponding measurements of the pressures, forces, and movementsdescribed herein or any other operational characteristics of the system.

In an example embodiment, the controller may be operative responsive tothe detection of slippage to cause the movable clamp device to providemore gripping force around the pipeline until the slippage of thepipeline ceases. Such additional gripping force may be achieved bycausing the one or more of the hydraulic cylinders to direct morepressure acting on different portions of the surface of the pipeline.The controller may monitor the resulting pressure detected by thepressure sensor for each hydraulic cylinder so as to adjust eachhydraulic cylinder in a manner that ensures that a uniform amount ofpressure is being applied to the pipeline.

In addition, the controller may monitor the pressure sensors todetermine that the amount of applied gripping force stays below apredetermined maximum threshold. The controller may also be operative tocause an output device to output an alarm signal or message responsiveto the detection of slippage by the movement sensor and/or the detectionby the thrust sensor of an amount force needed by the drives to move thepipeline which approaches (or surpasses) a predetermined maximumthreshold.

Such an alarm signal may be indicative of the pipeline experiencing anintermittent increase in resistance to being pushed through the bores.To overcome such resistance, the controller may be operativelyconfigured to be manually instructed via an input through an inputdevice, to cause an amount of gripping force to be applied with themovable clamp device that exceeds the predetermined maximum threshold.In other cases, the controller may be operatively configured to bemanually instructed via an input through the input device to cause theinsertion device to operate to partially pull the pipeline in a reverse(outwardly) direction, and then begin again pushing the pipeline forwardto attempt to move the pipeline passed the position that causes theincreased amount of resistance.

Also in other cases to overcome such resistance, the controller may beoperatively configured to adjust the speed of movement of the movableclamp device relative the inserter frame. For example, for somesituations, the controller may cause the drives to move the movableclamp device faster to push the pipeline past a position that causesresistance. In other situations, the controller may cause the drives tomove the movable clamp device slower until the thrust sensors detectthat the resistance forces have decreased.

Example embodiments may also include other types of sensors ormonitoring devices. For example sensors may be used that monitor theamount of wear on the shoes/pads of the movable and/or stationary clampdevice. Also, example embodiments may include a plurality of videocameras positioned to monitor different operational aspects of thesystem. For example, the system may include a video camera that ispositioned to monitor the insertion device, as well as video camerasoperative to monitor one or more frame supports.

All or portions of the information collected from the video cameras,sensors, and the operational data associated with the controller and thedescribed system may be provided through output devices locally near thesystem (e.g., in a operation cabin/trailer) or remote from the system(e.g., a workstation connected to the system via network such as theInternet). Also, such information may be collected in one or more datastores for use with analyzing the operational characteristics of thesystem.

As described previously, additional pipeline segments are welded on theend of the pipeline to lengthen the pipeline near the insertion device.In an example embodiment, such additional pipeline segment may besupported by movable supports having rollers and/or lifting mechanismthat allow the new pipeline segment to be moved into proper alignmentfor welding. Such additional pipeline segments may also be tested priorto operating the insertion device to move the newly added pipelinesegments into the bores of the housing segments.

With reference now to FIG. 9, an example methodology is illustrated anddescribed associated with the operation of the previously describedexample pipeline insertion system to insert a pipeline into the bores ofhousing segments within a tunnel. While the methodology is described asbeing a series of acts that are performed in a sequence, it is to beunderstood that the methodologies are not limited by the order of thesequence. For instance, some acts may occur in a different order thanwhat is described herein. In addition, an act may occur concurrentlywith another act. Furthermore, in some instances, not all acts may berequired to implement a methodology described herein.

Moreover, some of the acts described herein may be caused bycomputer-executable instructions that can be implemented by one or moreprocessors and/or stored on a non-transitory computer-readable medium ormedia. The computer-executable instructions may include a routine, asub-routine, programs, a thread of execution, and/or the like. Stillfurther, results of acts of the example methodologies may be stored in acomputer-readable medium, displayed on a display device, and/or thelike.

As illustrated in FIG. 9, the methodology 900 begins at 902, and at 904includes a step of clamping at least one portion of a pipeline with amovable clamp device included in a pipeline insertion device. At step906, the method includes moving the movable clamp device with the atleast one drive from a first position to a second position in a firstdirection along the frame, which causes portions of the pipeline to movewithin bores in a plurality of housing segments and within channels in aplurality of spaced apart support frames.

Continuing at step 908, the methodology may include a step of releasingthe at least one portion of the pipeline from being clamped with themovable clamp device. Also at step 910, the methodology may include astep of moving the movable clamp device with the drive from the secondposition to the first position in a second direction that is oppositethe first direction without moving the pipeline relative to the housingsegments and the support frames. In an example embodiment, a furtherstationary clamp device may be operative to clamp the pipeline andprevent the pipeline from moving while the movable clamp device returnsto the first position.

Steps 904 to 910 correspond to an insertion cycle. After one or morerepeated insertion cycles the methodology may include a step 912 ofwelding at least one pipeline segment to the pipeline on an end of thepipeline that is outside the bores of the housing segments. After thepipeline is lengthened in this manner, the described methodology may berepeated a sufficient number of times to insert an increasingly longerpipeline into the housing segments for the distance that is required forthe application. At 914 the described methodology may end.

As discussed previously, the housing segments and support frames mayinclude more than one bore and channel therethrough for use withinserting additional pipeline. In such cases, the described methodology900 may include repositioning the insertion device with the describedhydraulic dollies and jacks so as to align the insertion device withanother bore hole. The previously described methodology 900 may then becarried out to insert a further pipeline into the other bore holes inthe housing segments.

With reference now to FIG. 10, an example methodology is illustrated anddescribed associated with the operation of the previously describedexample pipeline insertion system to extract a pipeline from the boresof housing segments within a tunnel. This methodology 1000 begins at1002, and at 1004 includes a step of clamping at least one portion of apipeline with a movable clamp device included in a pipeline insertiondevice. At step 1006, the method includes moving the movable clampdevice with a drive from a second position to a first position in asecond direction along a frame, which causes portions of the pipeline tobe pulled out of a bore of at least one of a plurality of housingsegments and out of a channel of at least one of a plurality of spacedapart support frames.

Continuing at step 1008, the methodology may include a step of releasingthe at least one portion of the pipeline from being clamped with themovable clamp device. Also at step 1010, the methodology may include astep of moving the movable clamp device with the drive from the firstposition to the second position in a first direction without moving thepipeline relative to the housing segments and the support frames. In anexample embodiment, a stationary clamp device may be operative to clampthe pipeline and prevent the pipeline from moving while the movableclamp device returns to the first position.

Steps 1004 to 1010 correspond to an extraction cycle. After one or morerepeated extraction cycles, the methodology may include a step 1012 ofcutting at least one pipeline segment from the pipeline on an end of thepipeline that has been pulled outside the bores of the housing segments.After the pipeline is shortened in this manner, the describedmethodology may be repeated a sufficient number of times to extract adecreasingly shorter pipeline from the housing segments for the distancethat is required for the application. At 1014 the described methodologymay end.

In embodiments in which the housing segments and support frames includemore than one bore and channel therethrough, the described methodology1000 may include repositioning the insertion device with the describedhydraulic dollies and jacks so as to align the insertion device withanother bore hole. The previously described methodology 1000 may then becarried out to extract a further pipeline from the other bore holes inthe housing segments.

Methodologies 900 and 1000 have been described with respect to a processof inserting or extracting pipelines through bores in housing segmentsmounted in a bored out tunnel. However, it is to be understood that allor portions of the described methodologies and insertion systems may beadapted for use in other environments such as in wetlands and shorelineapproaches for pipelines. In such cases the insertion device may be usedto insert or extract a pipeline from the bore holes of other types ofpipeline housing segments that may not correspond to floor segmentshaving an upper surface usable as a roadway. It is to be understood thatthe element of a housing segment may include other types of structureshaving one or more bores therein and that can accommodate the placementof the previously described support frames on opposite ends of the boresthat extend through housing segments.

As used herein, the described at least one processor 112 may be includedin a computing device (such as a computer or a dedicated controller)that executes instructions that are stored in a memory as software orfirmware. The instructions may be, for instance, instructions forcausing devices of the described system to operate or instructions forimplementing one or more of the methods described above. The processormay access the memory by way of a system bus or other type of memorycontroller/bus.

Additionally, while illustrated as a single system, it is to beunderstood that the computing device may be a distributed system. Thus,for instance, the processor and several devices may be in communicationby way of a network connection and may collectively perform tasksdescribed as being performed by the described systems.

It is noted that several examples have been provided for purposes ofexplanation. These examples are not to be construed as limiting thehereto-appended claims. Additionally, it may be recognized that theexamples provided herein may be permutated while still falling under thescope of the claims.

What is claimed is:
 1. At least one non-transitory computer readablemedia comprising executable instructions operative to cause at least onecontroller in operative connection with a pipeline insertion device tocarry out a method comprising: a) through operation of the at least onecontroller, causing a movable clamp device included in the pipelineinsertion device to clamp at least one portion of a pipeline, whereinthe pipeline insertion device includes an insertion device frame, themovable clamp device in slidable engagement with the insertion deviceframe, and at least one drive, wherein the movable clamp device isoperative to move between a first position and a second position alongthe insertion device frame, wherein the movable clamp device isoperatively configured to change between a first state and a secondstate, wherein in the first state the movable clamp device is operativeto clamp the at least one portion of the pipeline and prevent relativemovement between the movable clamp device and the pipeline, wherein inthe second state the movable clamp device is operative to release the atleast one portion of the pipeline and permit relative movement betweenthe movable clamp device and the pipeline; and b) through operation ofthe at least one controller causing the at least one drive to move themovable clamp device from the first position to the second position in afirst direction along the frame, which causes portions of the pipelineto move within at least one bore in at least one of a plurality ofhousing segments and within at least one channel in at least one of aplurality of spaced apart support frames, wherein each channel of eachsupport frame includes at least one bearing mounted therein forreceiving portions of the pipeline in operatively sliding connectionwith the at least one bearing, wherein the support frames arerespectively positioned between the bores of adjacent housing segments,such that the bores of the housing segments and the channels of thesupport frames are aligned to receive the pipeline extending in asubstantially straight line therethrough; c) through operation of the atleast one controller, causing the movable clamp device to release the atleast one portion of the pipeline; and d) through operation of the atleast one controller, causing the at least one drive to move the movableclamp device from the second position to the first position in a seconddirection that is opposite the first direction without moving thepipeline relative to the housing segments and the support frames.
 2. Thecomputer readable media according to claim 1, wherein in (a) theinsertion device frame includes at least one stationary clamp device,wherein the movable clamp device is operative to move relative both theinsertion device frame and the stationary clamp device, wherein thestationary clamp device is operative to receive at least a portion ofthe pipeline therein, wherein the at least one controller is operativelyconfigured to cause the stationary clamp device to change between afirst state and a second state, wherein in the first state, thestationary clamp device is operative to clamp at least one furtherportion of the pipeline and prevent relative movement between thestationary clamp device and the pipeline, wherein in the second statethe stationary clamp device is operative to release the at least onefurther portion of the pipeline and permit relative movement between thestationary clamp device and the pipeline; wherein the method furthercomprises: e) prior to (b), through operation of the at least onecontroller causing the stationary clamp device to change to the secondstate so as to permit relative movement between the stationary clampdevice and the pipeline; f) subsequent to (b) and prior to (d) throughoperation of the at least one controller causing the stationary clampdevice to change to the second state so as to clamp at least one furtherportion of the pipeline and prevent relative movement between thestationary clamp device and the pipeline during (d).
 3. The computerreadable media according to claim 1, wherein in (a) the movable clampdevice includes at least one stationary portion and at least one movableportion, wherein (a) includes the at least one controller causing the atleast one movable portion to move between a first position and a secondposition relative to the at least one stationary portion, wherein the atleast one movable portion in the first position rigidly clamps thepipeline between the at least one stationary portion and the at leastone movable portion, wherein the at least one movable portion in thesecond position is relatively farther from the at least one stationaryportion than when the at least one movable portion is in the firstposition, wherein the first state of the movable clamp device includesthe at least one movable portion in the first position, wherein thesecond state of the movable clamp device includes the at least onemovable portion in the second position.
 4. The computer readable mediaaccording to claim 3, wherein the movable clamp device includes at leastthree movable portions positioned to move in three different respectiveradial directions with respect to a longitudinal axis of the pipeline,wherein the movable portions include pads that are operative to contactthe outer surface of the pipeline, wherein the movable clamp deviceincludes hydraulic cylinders which are operative to selectively move thepads of the movable portions between the first and second states,wherein (a) includes the at least one controller causing the hydrauliccylinders to operate.
 5. The computer readable media according to claim3, wherein the pipeline insertion device includes at least one firstsensor operatively configured to be used by the at least one controllerto determine if the pipeline moves relative to the movable clamp devicewhen the at least one controller causes the at least one drive to movethe movable clamp device relative to the insertion device frame, wherein(b) includes the at least one controller causing the at least onemovable portion of the movable clamp device to provide an increasedamount of force to be applied to the pipeline by the movable portionresponsive to the first sensor detecting relative movement between themovable clamp device and the pipeline.
 6. The computer readable mediaaccording to claim 5, wherein the pipeline insertion device includes atleast one second sensor operatively configured to monitor an amount ofpressure applied to the pipeline by the at least one movable portion ofthe movable clamp device, wherein (b) includes the at least onecontroller preventing the at least one movable portion of the movableclamp device from providing an amount of pressure on the pipeline thatexceeds a predetermined threshold responsive to the at least one secondsensor.
 7. The computer readable media according to claim 1, wherein thepipeline insertion device includes at least one first sensor operativelyconfigured to monitor an amount of force applied to the pipeline in theat least one direction by the movable clamp device when being caused tomove by the at least one drive, wherein (b) includes the at least onecontroller causing the at least one drive to adjust the speed ofmovement of the movable clamp device relative to the frame responsive tothe at least one first sensor.